Processor controlled circuit breaker trip system having an intelligent rating plug

ABSTRACT

A rating plug circuit is used in a processor-based circuit breaker tripping system having a current sensor for sensing current from a current path. The rating plug circuit includes a printed circuit board and a resistor that is connected to the printed circuit board for establishing a designated voltage in the presence of a predetermined amount of sensed current. A connector, having a plurality of conductive contact points, interconnects the printed circuit board with the tripping system, and a plurality of printed circuit paths are included on the printed circuit board to provide a binary code at the contact points. The binary code indicates the value of the resistor and is read by the processor to analyze the current in the current path.

TECHNICAL FIELD

The present invention relates generally to circuit breakers, and, moreparticularly, to processor controlled trip arrangements for circuitbreakers.

BACKGROUND ART

Trip systems are designed to respond to power faults detected in circuitbreakers. Most simple trip systems employ an electromagnet to trip thecircuit in response to short circuit or overload faults. Theelectromagnet provides a magnetic field in response to the currentflowing through the breaker. When the current level increases beyond apredetermined threshold, the magnetic field "trips" a mechanism whichcauses a set of circuit breaker contacts to release, thereby "breaking"the circuit path.

Many simple trip systems also employ a slower responding bi-metallicstrip, which is useful for detecting a more subtle overload fault. Thisis because the extent of the strip's deflection represents an accuratethermal history of the circuit breaker and, therefore, even slightcurrent overloads. Generally, the heat generated by the current overloadwill cause the bi-metallic strip to deflect into the tripping mechanismto break the circuit path.

The tripping systems discussed above are generally adequate for manysimple circuit breaker applications, but there has been an increasingdemand for a more intelligent and flexible tripping system. For example,many industries today include three-phase power equipment that must beadjusted and monitored on a regular basis. Processor-based trippingsystems have been developed to meet these needs.

To permit the tripping systems to be set for a selected current ratingsand other tripping specifications, the systems have included jumperwires or other control mechanisms. In addition, to cover a wide range ofselectable current ratings, the tripping systems have included complexcalibration circuits having multiple calibration outputs. Moreover, thecalibration circuits are relatively expensive because they includeprecision resistors for precise current measurements.

SUMMARY OF INVENTION

A preferred embodiment of the present invention includes a rating plugcircuit for use in a fault-powered, processor-based circuit breakertripping system having a current sensor for inducing current from acurrent path. The rating plug circuit includes a printed circuit boardand at least one resistor that is connected to the printed circuit boardfor establishing a designated voltage in the presence of a predeterminedamount of induced current. A connector, having a plurality of conductivecontact points, interconnects the printed circuit board with thetripping system, and a plurality of printed circuit paths are includedon the printed circuit board to provide a binary code at the contactpoints to indicate the value of the resistor. The processor then readsthe contact points to analyze the current in the current path.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects and advantages of the invention will become apparent uponreading the following detailed description and upon reference to theaccompanying drawings, in which:

FIG. 1 is a block diagram of a microprocessor based circuit breakertripping system, according to the present invention;

FIG. 2 is a perspective view of the circuit breaker tripping system asset forth in the block diagram of FIG. 1;

FIG. 3a is a diagram illustrating a local display 150 of FIG. 1;

FIG. 3b is a flow chart illustrating a manner in which a displayprocessor 316 of FIG. 3a may be programmed to control an LCD display 322of FIG. 3a;

FIG. 4 is a schematic diagram illustrating an analog input circuit 108,a ground fault sensor circuit 110, a gain circuit 134 and a power supply122 of FIG. 1;

FIG. 5 is a timing diagram illustrating the preferred manner in whichsignals received from the gain circuit 134 are sampled by themicrocomputer 120 of FIG. 1;

FIG. 6a is a side view of a rating plug 531 of FIG. 4;

FIG. 6b is a top view of the rating plug 531 of FIG. 4;

FIG. 7 is a schematic diagram illustrating a thermal memory 138 of FIG.1;

FIG. 8 is a schematic diagram illustrating the reset circuit 124 of FIG.1; and

FIG. 9 is an illustration of a user select circuit 132 of FIG. 1.

While the invention is susceptible to various modifications andalternative forms, a specific embodiment thereof has been shown by wayof example in the drawings and will herein be described in detail. Itshould be understood, however, that it is not intended to limit theinvention to the particular form disclosed, but on the contrary, theintention is to cover all modifications, equivalents, and alternativesfalling within the spirit and scope of the invention as defined by theappended claims.

BEST MODES FOR CARRYING OUT THE INVENTION System Overview

The present invention has direct application for monitoring andinterrupting a current path in an electrical distribution systemaccording to specifications that may be programmed by the user. Whileany type of current path would benefit from the present invention, it isparticularly useful for monitoring and interrupting a three phasecurrent path.

Turning now to the drawings, FIG. 1 shows a block diagram of an integralmicroprocessor controlled tripping system 100 for use with a three-phasecurrent path on lines 106 having source inputs 102 and load outputs 104.The tripping system 100 uses an analog input circuit 108 and a groundfault sensor 110 to detect three-phase current on the current path 106.When the tripping system detects an overload, short circuit or groundfault condition, or otherwise determines that the current path should beinterrupted, it engages a solenoid 112 which trips a set of contactors114 to break the current path carrying phases A, B and C. Consequently,any ground-fault circuit through the earth ground path or through anoptional neutral line (N) is also broken.

The tripping system 100 of FIG. 1 utilizes a number of circuits todetermine when the current path should be interrupted. Thisdetermination is centralized at a microcomputer 120, preferably anMC68HC11A1, which is described in MC68HC11 HCMOS Single ChipMicrocomputer Programmer's Reference Manual, 1985 and MC68HC11A8 AdvanceInformation HCMOS Single Chip Microcomputer, 1985, all being availablefrom Motorola, Inc., Schaumburg, Ill. Peripheral circuits that supportthe microcomputer 120 include a reset circuit 124 that verifies thesanity of the tripping system 100, a voltage reference circuit 126 thatprovides a stable and reliable reference for analog to digital (A/D)circuitry located within the microcomputer 120, ROM 128 that stores theoperating instructions for the microcomputer 120, and a conventionaladdress and data decoding circuit 130 for interfacing the microcomputer120 with various circuits including the ROM 128 and a user selectcircuit 132. The address and data decoding circuit 130, for example,includes an address decoder part No. 74HC138, and an eight-bit latch,part No. 74HC373, to latch the lower eight address bits which arealternately multiplexed with eight data bits in conventional fashion.The ROM, for example, is part No. 27C64. The user select circuit 132allows the user to designate tripping characteristics for the trippingsystem 100, such as overload and phase imbalance fault conditions.

The tripping system 100 is operatively coupled with a conventionalelectrical distribution system (not shown) through input and outputrestraint circuits 105 and 107. Signals received from the inputrestraint circuit 105 indicate that a downstream circuit breaker is inan overload (or over current) condition. The output restraint circuit107 is used to send signals to upstream circuit breakers to indicate thestatus of its own and all downstream circuit breaker conditions. Ingeneral, the tripping system 100 will delay tripping of the contactors114 when a downstream breaker is in an overload (or over current)condition, assuming that the downstream circuit breaker opens and clearsthe condition. Otherwise, the tripping system 100 should not delaytripping of the contactors 114. For further detail regardingrestraint-in/restraint-out electrical distribution systems, referencemay be made to U.S. Pat. No. 4,706,155 to Durivage et al.

Other circuits are used along with the above circuits to providereliability and integrity to the tripping system 100. For instance, themicrocomputer 120 utilizes the analog input circuit 108 along with again circuit 134 to measure precisely the RMS (Root Mean Squared)current on each phase of the lines 106. The accuracy of this measurementis maintained even in the presence of non-linear loads.

The analog input circuit 108 develops phase signals A', B' and C' thatare representative of the current on lines 106. The gain circuit 134amplifies each phase signal A', B' and C' through respective dual gainsections, from which the microcomputer 120 measures each amplifiedsignal using its A/D circuitry. By providing two gain stages for eachsignal A', B' and C', the microcomputer 120 can immediately perform ahigh gain or low gain measurement for each current phase depending onthe resolution needed at any given time.

The analog input circuit 108 is also utilized to provide a reliablepower source to the tripping system 100. Using current developed fromthe lines 106, the analog input circuit 108 operates with a power supply122 to provide three power signals (VT, +9 v and +5 v) to the trippingsystem 100. The power signal VT is monitored by the microcomputer 120through decoding circuit 130 to enhance system dependability.

System dependability is further enhanced through the use of a thermalmemory 138 which the microcomputer 120 interacts with to simulate abi-metal deflection mechanism. The thermal memory 138 provides anaccurate secondary estimate of the heat in the tripping system 100 inthe event power to the microcomputer 120 is interrupted.

The ground fault sensor 110 is used to detect the presence of groundfaults on one or more of the lines 106, and to report the faults to themicrocomputer 120. Using user selected trip characteristics, themicrocomputer 120 determines whether or not the ground fault is presentfor a sufficient time period at a sufficient level to trip thecontactors 114. The microcomputer 120 accumulates the ground fault delaytime in its internal RAM. A RAM retention circuit 140 is used topreserve the ground fault history for a certain period of time duringpower interruptions.

The RAM retention circuit 140 exploits the built-in capability of themicrocomputer 120 to hold the contents of its internal RAM provided thatan external supply voltage is applied to its MOPDB/Vstby input 141. Thisexternal supply voltage is stored on a 150 microfarad electrolyticcapacitor 143 that is charged from the +9 volt supply through a 6.2 Kohm resistor 145. The capacitor 143 is charged from the +9 volt supply,and clamped by diodes to the +5 volt supply, so that the capacitor willbe rapidly charged during power-up.

The ground fault delay time stored in internal RAM becomes insignificantafter a power interruption that lasts longer than about 3.6 seconds. Totest whether such an interruption has occurred, the RAM retentioncircuit 140 includes an analog timer 149 having a resistor 161 and acapacitor 153 establishing a certain time constant, and a Schmitttrigger inverter 155 sensing whether the supply of power to themicrocomputer 120 has been interrupted for a time sufficient for thecapacitor 153 to discharge. Shortly after the microcomputer reads theSchmitt trigger 155 during power-up, the capacitor 153 becomes rechargedthrough a diode 157 and a pull-up resistor 159. Preferred componentvalues, for example, are 365 K ohms for resistor 161, 10 microfarads forcapacitor 153, part No. 74HC14 for Schmitt trigger 155, 1N4148 for diode157, and 47 K ohms for resistor 159.

Another important aspect of the tripping system 100 is its ability totransfer information between itself and the user. This informationincludes the real-time current and phase measurements on the lines 106,the system configuration of the tripping system 100 and informationrelating to the history of trip causes (reasons why the microcomputer120 tripped the contactors 114). As discussed above, the real-time linemeasurements are precisely determined using the analog input circuitry108 and the gain circuit 134. The system configuration of the trippingsystem 100 and other related information is readily available from ROM128 and the user select circuit 132. The information relating to thehistory of trip causes is available from a nonvolatile trip memory 144.Information of this type is displayed for the user either locally at alocal display 150 or remotely at a conventional display terminal 162 viaremote interface 160. To communicate with the display terminal 162, thetripping system utilizes an asychronous communication interface,internal to the microcomputer 120. Using the MC68HC11, the serialcommunications interface (SCI) may be utilized.

FIG. 2 is a perspective view of the tripping system 100 as utilized in acircuit breaker housing or frame 210. The lines 106 carrying phasecurrents A, B and C are shown passing through line embedded currenttransformers 510, 512 and 514 (in dashed lines) which are part of theanalog input circuit 108. Once the solenoid 112 (also in dashed lines)breaks the current path in lines 106, the user reconnects the currentpath using a circuit breaker handle 220.

Except for the circuit breaker handle 220, the interface between thetripping system 100 and the user is included at a switch panel 222, anLCD display panel 300 and a communication port 224. The switch panel 222provides access holes 230 to permit the user to adjust binary codeddecimal (BCD) dials (FIG. 8) in the user select circuit 132. Thecommunication port 224 may be used to transfer information to thedisplay terminal 162 via an optic link (not shown).

In the following sections, the tripping system 100 is further describedin detail.

A. Local Display

FIG. 3a is a schematic diagram of the local display 150 of FIG. 1. Thelocal display 150 is physically separated from the remaining portion ofthe tripping system 100, but coupled thereto using a conventionalconnector assembly 310. The connector assembly 310 carries a pluralityof communication lines 312 from the microcomputer 120 to the localdisplay 150. These lines 312 include tripping system ground, the +5 Vsignal from the power supply 122, serial communication lines 314 for adisplay processor 316, and data lines 318 for a latch 320. The datalines 318 include four trip indication lines (overload, short circuit,ground fault and phase unbalance) which are clocked into the latch 320by yet another one of the lines 318.

An LCD display 322 displays status information provided by the latch 320and the display processor 316. Different segments of the LCD display 322may be implemented using a variety of devices including a combinationstatic drive/multiplex custom or semi-custom LCD available from Hamlin,Inc., Lake Mills, Wis. For additional information on custom orsemi-custom displays, reference may be made to a brochure available fromHamlin, Inc. and entitled Liquid Crystal Display.

The latch 320 controls the segments 370-373 to respectively indicate thetrip conditions listed above. Each of these segments 370-373 iscontrolled by the latch 320 using an LCD driver circuit 326 and anoscillator circuit 328. The corresponding segment 370-373 illuminateswhen the associated output signal from the latch 320 is at a logic highlevel.

The display processor 316 controls four seven-segment digits 317 as anammeter to display the current in the lines 106. The display processor316, for example, is an NEC part No. UPD7502 LCD Controller/Driver whichincludes a four-bit CMOS microprocessor and a 2 k ROM. This NEC part isdescribed in NEC UPD7501/02/03 CMOS 4-Bit Single Chip MicroprocessorUser's Manual, available from NEC, Mountain View, Calif. Other segments375 of the LCD display 322 may be controlled by the display processor316 or by other means to display various types of status messages.

For example, a push button switch 311 may be utilized to test a battery338. To perform this test, the battery 338 is connected through a diode313 to one of the segments 375 so that when the switch 311 is pressed,the condition of the battery is indicated. The push-button switch 311preferably resets the latch 320 when the switch is depressed. For thispurpose the switch 311 activates a transistor 315. The latch, forexample, is a 40174 integrated circuit.

Additionally, the switch 311 may be used to select the phase current tobe displayed on the LCD display 322 to control segments 375 such thatthey identify the phase current (A, B, C or N) on lines 106 beingdisplayed on the four seven-segment digits 317. For this purpose theswitch 311 activates a transistor 327 to invert a signal provided fromthe battery and to interrupt the display processor 316. Each time thedisplay processor 316 is interrupted, the phase current that isdisplayed changes, for example, from phase A to B to C to ground faultto A, etc.

An optional bar segment 324 is included in the LCD display 322 toindicate a percentage of the maximum allowable continuous current in thecurrent path. The bar segment 324 is controlled by the +5 V signal via aseparate LCD driver 330. The LCD driver 330 operates in conjunction withthe oscillator circuit 328 in the same manner as the LCD driver 326.However, the LCD driver 330 and the oscillator circuit 328 will functionat a relatively low operating voltage, approximately two to three volts.An MC14070 integrated circuit, available from Motorola, Inc., may usedto implement the LCD drivers 330 and 326. Thus, when the tripping systemfails to provide the display processor 316 with sufficient operatingpower (or current), the LCD driver 330 is still able to drive the barsegment 324. The LCD driver 330 drives the bar segment 324 whenever thetripping system detects that less than about 20% of the rated tripcurrent is being carried on lines 106 to the load.

As an alternative embodiment, the bar segment 324 may be disabled bydisconnecting the LCD driver 330.

Additional bar segments 332-335 are driven by the display processor 316to respectively indicate when at least 20-40%, 40-60%, 60-80% and80-100% of the rated trip current is being carried on lines 106 to theload.

The oscillator 328 also uses part No. MC14070 in a standard CMOSoscillator circuit including resistors 329, 336 and a capacitor 331 thathave values, for example, of 1 megohm, 1 megohm, and 0.001 microfarads,respectively.

Even when a power fault causes the system to trip and interrupt thecurrent on lines 106, the local display is still able to operate on alimited basis. This sustained operation is performed using the battery338 as a secondary power source. The battery, for example, is a 3 to 3.6volt lithium battery having a projected seventeen year life. The battery338 supplies power to portions of the local display 150 only when twoconditions are present: (1) the latch 320 has received a trip signalfrom the microcomputer 120 (or the test switch 311 is activated), and(2) the output voltage level of the +5 V power supply is less than thevoltage level from the battery 338. When the latch 320 latches in anyone of the four trip indication lines from the data lines 318, a controlsignal is generated on a latch output line 340. The control signal turnson an electronic switch 342 which allows the battery 338 to providepower at Vcc so long as a diode 344 is forward biased.

The diode 344 is forward biased whenever the second condition is alsopresent. Thus, when the output voltage level of the +5 V power supply isless than the voltage level from the battery 338, the diode 344 isforward biased and the battery 338 provides power to the local display150. In addition, the diode 344 is forward biased until a switch 346,activated by a power-up circuit 348, allows the +5 V signal to providepower at Vcc. The power-up circuit 348 activates the electronic switch346 only after resetting the display processor 316. The power-up circuit348, for example, is part No. ICL7665 working in connection withresistors 349, 351, and 353 having values of 620 K ohms, 300 K ohms and10 megohms, respectively.

Power is provided from Vcc only to the latch 320, the LCD driver 326,the LCD driver 330, and the oscillator circuit 328. The LCD driver 330and the oscillator circuit 328 receive power from either the battery 338or the +5 V power supply output via diodes 350 and 352. This arrangementminimizes current drain from the battery 338 while allowing the user toview the status of the tripping system 100 during any power faultsituation.

Power cannot be drawn from the battery 338 unless the battery 338 isinterconnected with the remaining portion of the tripping system viaconnector 310, because the connector 310 provides the ground connectionfor the negative terminal of the battery 338. This aspect of the localdisplay 150 further prolongs battery life and therefore minimizes systemmaintenance.

In FIG. 3b, a flow chart illustrates the preferred programming of thedisplay processor 316. The flow chart begins at block 376 where thememory internal to the display processor is initialized. The memoryinitialization includes clearing internal RAM, input/output ports andinterrupt and stack registers.

At block 378, a software timer is reset and the display processor waitsfor a data ready flag which indicates that data has been received fromthe microcomputer 120 of FIG. 1. The software timer provides aconventional software watchdog function to maintain the sanity of thedisplay processor. If the software timer is not reset periodically(within a certain time interval), the display processor resets itself.

The data ready flag is set in an interrupt routine, illustrated byblocks 390 through 398 of FIG. 3b. The display processor is programmedto execute the interrupt routine when it receives data from themicrocomputer 120 of FIG. 1. At block 390 of the interrupt routine, atest is performed to determine if the data byte just received is thelast data byte of the packet sent from the microcomputer. If the databyte just received is not the last data byte, flow proceeds to block 398where a return-from-interrupt instruction is executed. If the data bytejust received is the last data byte, flow proceeds to block 392.

At block 392, a test is performed to determine the integrity of thereceived data packet. This is accomplished by comparing the 8-bit sum ofthe previously received 7 bytes with the most recently received byte(last byte). If the 8-bit sum and the last byte are different, flowproceeds to block 398. If the 8-bit sum and the last byte are the same,the display processor sets the previously referred to data ready flag,depicted at block 396, and returns from the interrupt, via block 398, toblock 380.

At block 380, the received data is stored in memory and the data readyflag is reset.

At blocks 382 and 384, the display processor utilizes a conventionalconversion technique to convert the stored data to BCD format fordisplay at the LCD display 322 of FIG. 3a. The data that is sent anddisplayed at the LCD display 322 is chosen by the operator using theswitch 311 to sequence through each of the three phase currents and theground fault current, as indicated in the data that is received from themicrocomputer 120 of FIG. 1.

At block 386, the display processor utilizes received data, includingthe sensor identification, the rating plug type and the long-time pickuplevel, to determine the percentage of rated trip current being carriedon lines 106 of FIG. 1. At block 388, the bar segments (324 and 332-335of FIG. 3a) are driven by the display processor in response to thisdetermination. From block 388, flow returns to block 378.

Blocks 400-406 of FIG. 3b represent a second interrupt routine which thedisplay processor may be programmed to execute in response to thedepression of the switch 311. At block 400 of this second interruptroutine, the display processor determines which phase (or ground fault)current the operator has selected by depressing the switch 311. Atblocks 402 and 404, the display processor monitors its I/O port todetermine when the switch 311 is released and to debounce the signalreceived from the switch 311. At block 406, the display processorexecutes a return from interrupt command.

It should be noted that the display processor 316 is optional for thelocal display 150 and therefore not required for its operation. Further,the local display 150 is itself an option to the tripping system and isnot required for operating the tripping system.

B. Current and Ground Fault Detection

FIG. 4 illustrates an expanded view of the analog input circuit 108, theground fault sensor 110, the power supply 122 and the gain circuit 134of FIG. 1. Each of these circuits receives power from the three-phasecurrent lines 106. Using this power, these circuits provide signals fromwhich the tripping system 100: (1) determines the phase and currentlevels on lines 106, (2) detects the presence of any ground fault, (3)provides system power and (4) establishes its current rating.

(1) Determining Phase and Current Levels

In FIG. 4, the analog input and ground fault sensing circuits 108 and110 include current transformers 510, 512 and 514 that are suitablylocated adjacent the lines 106 for receiving energy from each respectivephase current path A, B, and C. Each current transformer 510, 512 and514 is constructed to produce a current output that is proportional tothe primary current in a fixed ratio. This ratio is set so that when theprimary current is 100% of the rated current transformer size (or sensorsize), the current transformer is producing a fixed output currentlevel. For example, for a 200 Amp circuit breaker, each currenttransformer 510, 512 and 514 will produce the same current output signalwhen operating at 100% (200 Amps) as a current transformer in a 4000 Ampcircuit breaker which it is operating at 100% (4000 Amps). The preferredconstruction yields a current transformer output current of 282.8milliamperes (RMS) when the primary current is 100% of the ratedcurrent.

The output currents provided by the transformers 510, 512 and 514 arerouted through a ground fault sensing toroid 508, full wave rectifierbridges 516, 518 and 520 and the power supply 122 to tripping systemground. The output currents are returned from tripping system groundthrough a burden resistor arrangement 530. The ground fault sensingtoroid 508 sums the output currents from the transformers 510, 512 and514. In a system utilizing a neutral (N) line 106, the ground faultsensing toroid also sums the output current from a transformer 506,which is coupled to the neutral line (N) to sense any return current. Asignal representing this current summation is produced at an outputwinding 509 and is carried to a fourth rectifier bridge 522. Therectifier bridge 522 is used to detect ground fault conditions and isdiscussed in the second part of this section.

On the right (positive) side of the rectifier bridges 516-522, positivephase current signals are produced and added together at lead 524. Thecurrent at lead 524 is used for the power supply 122 which is discussedin the third part of this section.

On the left (negative) side of the rectifier bridges 516-520, negativephase current signals are carried through the burden resistorarrangement 530 and tripping system ground, and are returned to therectifier bridges 516-520 through the power supply 122. This currentpath establishes voltage signals A', B' and C', each referred to as aburden voltage, for measurement by the microcomputer 120 via the gaincircuit 134.

In FIG. 4, the signals A', B' and C' are presented to the respectivedual gain sections for inversion and amplification. The gain circuit 134of FIG. 4 is shown with one of its three identical dual gain sections,generally designated as 533, in expanded form. The dual gain section 533receives phase signal A'. Each dual gain section includes a pair of lowpass filters 532 and a pair of amplifiers 534 and 536. The low passfilters 532 provide noise suppression, and the amplifiers 534 and 536reduce the signal magnitude by 0.5 and increase the signal magnitude bya factor of 3, respectively, for the desired resolution. Thisarrangement allows the microcomputer 120 to instantaneously measurethese current levels without wasting time changing any gain circuitry.Preferred component values are, for example, 10 K ohms for resistors541, 543, 545, 553 and 555; 4.75 K ohms for resistors 547 and 559; 60 Kohms for resistor 557; and 0.03 microfarads for capacitors 549 and 561.The amplifiers 551 and 663 are, for example, part No. LM124.

Using the gain circuit 134, the microcomputer 120 measures the true RMScurrent levels on lines 106 by sampling the burden voltages developed atsignals A', B' and C'. The RMS calculations are based on the formula:##EQU1## where:

N=the number of samples;

t=time at discrete intervals (determined by sample rate); and

I(t)=the instantaneous value of the current flowing through the breaker.

The current flowing through the circuit breaker is sampled at fixed timeintervals, thereby developing I(t). The value of this instantaneouscurrent sample is squared and summed with other squared samples for afixed number of samples N. The mean of this summation is found bydividing it by N. The final RMS current value is then found by takingthe square root of the mean.

In FIG. 5, an example of a rectified sinusoidal current waveform isillustrated for 1.5 cycles of a 60 hertz signal with a peak amplitude of100 amps. The sampled current is full wave rectified. The vertical linesrepresent the discrete points in time that a value of current issampled. With a sample rate of 0.5 milliseconds, over 25 milliseconds oftime, 50 samples will be taken.

In TABLE 1, the data for the samples from FIG. 4 are illustrated in thecolumn labeled I(t) (Amps). The column labeled I(t) SQUARED (Amps) givesthe squared values, and the column labeled SUMMATION (Amps) shows theaccumulation of the squared current values over time. The mean of thesummation, depicted at the bottom of TABLE 1, is equal to the finalaccumulation divided by the number of samples, or 50. The square root ofthis value yields 70.7106854, which is less than 0.00001% in error.

The other columns in TABLE 1 detail the binary equivalent data that themicrocomputer would process using the ratio that 100 amps equals 255binary.

The value I_(FMS) will accurately reflect the heating effect of thecurrent waveform that existed from t=0 to t=N. This current waveform istypically an A.C. waveform with a fundamental frequency of 50 to 60Hertz, but may contain many upper harmonics (i.e., multiples of thefundamental frequency).

In practical implementations, several factors affect the accuracy of theI_(RMS) calculation, including the sample rate and the number ofsamples. In the preferred embodiment, the sample rate is 2,000 Hertz andat least 128 samples are taken before the current magnitude isestimated.

(2) Detecting The Presence Of A Ground Fault

The ground fault sensing toroid 508 magnetically adds the currentsignals from the input windings 540, 542, 544 and 546 to indicatewhether or not a ground fault is present on lines 106. The toroid 508 isconstructed with four identical input windings 540, 542, 544 and 546;one for each of the current transformers 510, 512 and 514 and one forthe neutral current path transformer 506, which is optional. The toroid508 has a single output winding 509 which provides a summed currentsignal.

The ground fault sensing toroid 508 includes another winding 550 toallow a test signal to be applied at terminals 552. Using momentaryswitch 554, the test signal creates a pseudo ground fault for thetripping system. The tripping system reacts to this pseudo ground faultin the same manner as a true ground fault. The test winding 550 isprotected by a positive coefficient resistor 556 that increases itsresistance as it heats, thereby limiting the current through it and thewinding 550. The positive coefficient resistor is, for example, aKeystone PTC Resettable Fuse, part No. RL3510-110-120-PTF. The testwinding 550 eliminates the need for a separate test transformer whichhas been utilized by systems in the prior art.

The operation of the ground fault sensing toroid 508 is best understoodby considering the operation of the tripping system with a ground faultand without a ground fault. In a balanced three phase system without aground fault, the current magnitude in each phase is equal but 120degrees out of phase with the other phases, and no neutral currentexists; thus, the output winding 509 produces no current. As the currentthrough any phase (A, B or C) increases, the current in the neutral pathis vectorially equal in magnitude but opposite in direction to theincrease in phase current, and the magnetic summation is still zero.When a ground fault is present, current flows through an inadvertentpath to an earth grounded object, by-passing the neutral transformer 506and creating a current signal in the transformer 509. Thus, thetransformer 509 produces a current signal only when a ground fault ispresent.

The current signal from the output transformer 509 of the ground faultsensing toroid 508 is routed through the rectifier bridge 522, the powersupply 122 and returned through the burden resistor arrangement 530. Theburden resistor arrangement 530 and the rectifier bridge 522 convertthat current signal into an A.C. rectified signal 558 that is invertedwith respect to tripping system ground, and that has a voltage that isproportional to the current in the transformer 509.

The A.C. rectified signal 558 is filtered by filter 560 for noisesuppression and then inverted using analog invertor 562. From the analoginvertor 562, a positive going signal is carried to an A/D input at themicrocomputer 120. The microcomputer 120 measures the peak levels at theoutput of the analog invertor 562 to detect the presence of a groundfault. A conventional voltage divider switch 564 is controlled by themicrocomputer 120 to selectively reduce that signal by two thirds, asmay be required under severe ground fault conditions. Preferredcomponent values are, for example, 10 K ohms for resistors 565 and 567;20 K ohms for resistor 569; 19.6 K ohms for resistor 573; 10 K ohms forresistor 575; 0.033 microfarads for capacitor 577; part No. LM124 foramplifier 579; and part No. BS170 for IGFET 581.

(3) Providing System Power

Power for the tripping system is provided directly from the current onlines 106, and current on any one of the lines 106 can be used. Thisfeature allows the tripping system to power-up on any one of the threephases and to be powered when a ground fault on one or more of the phaselines 106 is present.

The output currents which are induced by the transformers 510, 512 and514 are routed through the rectifier bridges 516, 518, 520 and 522 toprovide the current for the power supply 122. On the right side of therectifier bridges 516-522, at lead 524, the output currents are summedand fed directly to a Darlington transistor 568, a 9.1 volts zener diode570 and a bias resistor 572. Most of this current flows directly throughthe transistor 568 to ground, to create a constant 9.1 volt level at thebase of the transistor 568. Because it has a nominal emitter to basevoltage (Veb) of about 1.0 volts, the emitter of the transistor 568 isat approximately 10 volts. The transistor 568 will strive to maintain 10volts across it from emitter to collector, regardless of the currentthrough it. Preferred component values are, for example, part No. 2N6285for Darlington transistor 568; 1N4739 for zener diode 570; and 220 ohmsfor resistor 572.

At the emitter of the transistor 568, the power signal VT ("tripvoltage") is provided.

The +5 v signal is a regulated +5 v power supply output signal that isprovided using a voltage regulator 571 (part No. LP2950ACZ-5.0) and acapacitor 582 which prevents the output of the regulator 571 fromoscillating. The voltage regulator takes its input from VT via a diode576. The diode 576 charges capacitor 584 to within one diode drop (0.6v) of VT and creates a second supply source of approximately +9 v, whichis referred to as the +9 V power supply. The energy stored in thecapacitor 584 enables the electronic circuitry being powered by the +9 Vpower supply to remain powered for some time after a trip occurs. Acapacitor 574, connected at the emitter of the transistor 568, aids infiltering voltage ripple. The capacitor 574 is also utilized as theenergy storage element for the solenoid 112 which is activated when apower IGFET 583 is turned on by "trip" signals from the microcomputer(120 in FIG. 1) or from a watchdog circuit (712 in FIG. 8). The tripsignals are combined by respective diodes 591, 593. The solenoid 112 isalso activated by an over-voltage condition sensed by a 16-volt zenerdiode 595, such as part No. 1N5246. Preferred component values are, forexample, 220 microfarads for capacitor 574, 100 microfarads forcapacitor 584, 10 microfarads for capacitor 582, 100 K ohms for resistor585, 10 K ohms for resistor 589, 0.1 microfarads for capacitor 587, andpart No. 6660 for IGFET 583.

Diodes 576 and 578 are used to receive current from an optional externalpower supply (not shown).

(4) Establishing The Current Rating

On the left side of the rectifier bridges, negative phase signals (A',B' and C') from the bridges are provided to the burden resistorarrangement 530, including a rating plug 531, to set the current ratingfor the tripping system. As previously discussed, when the primarycurrent is 100% of the rated current or "sensor size", which isdesignated using the user select circuit 132, the current transformeroutput current will be 282.8 milliamperes (RMS). Thus, when themicrocomputer 120 reads the burden voltages using the gain circuit 134(FIG. 1), the microcomputer 120 can calculate the actual current in thelines 106.

FIG. 4 illustrates parallel connections between respective resistors 527and 529 which are used to establish the maximum allowable continuouscurrent passing through the lines 106. The resistors 527 are part of therating plug 531, and the resistors 529 are separate from the rating plug531. The resistors 529, for example, are each 4.99 ohm, 1%, 5 wattresistors. This value should be compared to a corresponding value of12.4 ohms for the burden resistor 525 for the ground fault signal. Theresistors 527 of the rating plug are connected in parallel with theresistors 529 and hence cause a decrease in the combined resistance.Therefore, the resistors 529 set the minimum current rating for thetripping system. In a preferred arrangement, for example, the minimumcurrent rating corresponds to 40% of the maximum current rating. Theresistors 527 in the rating plug scale the voltages (A', B', C') read bythe microcomputer. This enables the resolution of the A/D converter inthe microcomputer to be the same in terms of a fraction of the ratedcurrent for both the minimum and maximum current rating. Consequently,there is not any sacrifice in converter resolution for the minimumcurrent rating.

In FIGS. 6a and 6b, the rating plug 531 is shown to include theresistors 527 mounted on a printed circuit board 587. A connector 588 isused to interconnect the rating plug with the remaining portion of thetripping system 100. When the rating plug is absent from the trippingsystem, the system reverts to its minimum rating.

The rating plug 531 further includes copper fusible printed circuitlinks A, B, C and D which are selectively disconnected (opened) from aprinted circuit connection 589 to inform the microcomputer 120 of theresistor values, or the burden voltage/current ratio, in the burdenresistor arrangement 530. The printed circuit connection 589 isconnected to the +5 V signal via one of the contact points on theconnector 588. This connection 589 allows the tripping system to encodethe printed circuit links A, B, C and D in binary logic such that one of16 values of each parallel resistor arrangement is defined therefrom. Ina preferred arrangement, the binary codes "1111" and "1110" are reservedfor testing purposes, and the fourteen codes "0000" to "1101" correspondto current rating multipliers of 0.400 to 1.000 as follows:

    ______________________________________                                                   Current                                                            Code       Rating Multiplier                                                  ______________________________________                                        0000       0.400                                                              0001       0.500                                                              0010       0.536                                                              0011       0.583                                                              0100       0.600                                                              0101       0.625                                                              0110       0.667                                                              0111       0.700                                                              1000       0.750                                                              1001       0.800                                                              1010       0.833                                                              1011       0.875                                                              1100       0.900                                                              1101       1.000                                                              ______________________________________                                    

The user select circuit 132 of FIG. 9 includes the interface circuitused by the microcomputer 120 to read the binary coded resistor valuefrom the rating plug 531. A tristate buffer 820 allows the microcomputer120 to selectively read the logic level of each of the four leadsrepresenting the status of the four fusible printed circuit links on therating plug 531. A logic high at the input of the buffer 820, providedby the connection between the fusible printed circuit link and +5 Vsignal, indicates that the corresponding link is closed. A logic low atthe input of the buffer 820, provided by pull-down resistors 826 at theinput of the buffer 820, indicates that the corresponding link is open.The fusible printed circuit links A, B, C and D may be opened using acurrent generator to send an excessive amount of current through thelinks, thereby causing the copper links to burn. This is preferablyperformed before the rating plug 531 is installed in the trippingsystem. Thus, once installed, the rating plug 531 automatically informsthe microcomputer 120 of its resistor values, and there is no need toadjust any settings or otherwise inform the microcomputer of the type ofrating plug being used. The microcomputer may adjust the values readfrom its A/D converter by a predetermined scale factor corresponding tothe binary coded resistor value to compute actual current values whichare independent of the resistor values in the rating plug 531.

C. Bi-metal Deflection Simulation

The microcomputer 120 is programmed to simulate accurately the bi-metaldeflection mechanism that is commonly used in processor-less trippingsystems. This is accomplished by accumulating the squared values of themeasured current samples that are sensed by the analog input circuit108. The sum of the squared values of that current is proportional tothe accumulated heat in the tripping system 100.

To simulate the bi-metal deflection during cooling, the microcomputer120 is programmed to decrement logarithmically the accumulated square ofthe current. In other words, during a sampling interval, the accumulatedvalue A of I(t)² is decremented by an amount proportional to A toaccount for the fact that the rate of heat loss is proportional to thetemperature of the power system conductors above ambient temperature. Inparticular, the temperature in the tripping system 100 decreases inresponse to the current path in lines 106 being broken or intermittent.When this occurs, however, the microcomputer 120 loses operating powerand therefore can no longer maintain this numerical simulation.

This problem is overcome by utilizing the thermal memory 138 of FIG. 1to maintain a history of the accumulated current for a predeterminedperiod of time during which the operating power to the microcomputer 120is lost. As illustrated in FIG. 7, this is accomplished using an RCcircuit 610 that is monitored and controlled by the microcomputer 120 tomaintain a voltage on the capacitor 611 that is proportional to theaccumulated square of the current. When the microcomputer loses power,the voltage across the RC circuit 610 logarithmically decays. (The decayis governed by the equation V=V₀ exp(-t/RC).) Should the microcomputerpower-up again before the voltage reaches zero, the microcomputer 120reads the voltage across the RC circuit 610 using a conventional analogbuffer 612 and initializes its delay accumulator to the correct value.The analog buffer 612, for example, includes an amplifier 627 such aspart No. LM714 and a 4.7 K ohm resistor 629.

The preferred RC circuit 610, including a 100 microfarad capacitor 611and a 3.24 megohm resistor 613, provides a fixed time constant of 324seconds, or approximately 5.4 minutes.

Control over the voltage on the RC circuit 610 is provided using IGFETtransistors 618 and 620, such as part Nos. VP0808 and BS170,respectively. During normal, quiescent conditions, the microcomputer 120will not be in an overload condition and will drive a logic low at thegate of the transistor 620, thereby disabling transistors 620 and 622and allowing the capacitor 611 to discharge to tripping system ground.Transistors 618 and 620 work in connection with resistors 621, 623 and625, which have values, for example, of 100 K ohms, 47 K ohms, and 5.1 Kohms, respectively.

During overload conditions, the microcomputer 120 accumulates currentinformation in its internal RAM to simulate the heat level, and drives alogic high at the gate of the transistor 620 to allow the capacitor 611to charge to a selected corresponding level. While the capacitor 611 ischarging, the microcomputer 120 monitors the voltage level using theanalog buffer 612. When the selected level is reached, the microcomputerdrives a logic low at the gate of the transistor 620 to prevent furthercharging. The voltage on the capacitor 611 is limited to five voltsusing a clamping diode 622. The forward voltage drop across the clampingdiode 622 is balanced by the voltage drop through a series diode 625.

For example, assume that an overload condition suddenly occurs and themicrocomputer 120 has been programmed to allow for a two minute delaybefore generating a trip signal at this overload fault level. After oneminute in this overload condition, the microcomputer 120 will haveaccumulated current information which indicates that it is 50% of theway to tripping. The microcomputer will also have enabled the RC circuit610 to charge to 2.5 v; that is, 50 % of the maximum 5 v. Assuming, forthe purpose of this example, that the overload fault condition isremoved at this point and the electronic trip system loses operatingpower, when the power to the microcomputer 120 drops to Ov, theinternally stored current accumulation is lost. However, the voltageacross the RC circuit 610 is still present and will start to decay byapproximately 63.2% every 5.4 minutes (the time constant for the RCcircuit 610). Therefore, after 5.4 minutes without current, the voltageacross the RC circuit 610 will be 36.8% of 2.5 v, or 0.92 v.

If the overload condition would occur again at this point, themicrocomputer 120 would power up and measure 0.92 v across the RCcircuit 610. The microcomputer 120 would then initialize its internalcurrent accumulation to approximately 18% (0.92 v divided by the maximumof 5.0 v) of the preprogrammed full trip delay time.

The accumulation calculations performed by the microcomputer are basedon the formula: ##EQU2## where:

N=the number of samples;

t=time at discrete intervals (determined by the accumulation rate); and

I(t)=the true RMS value of current through the breaker.

During a fault, the trip unit will begin to sum the current squaredvalue as soon as the current exceeds a predetermined level for apredetermined period of time, or the selected overload condition. Theelectronic trip system will maintain an internal accumulation registerto store a value that is proportional to the square of the current andthat is incremented periodically based on the accumulation rate.Assuming a constant fault level of current, a fixed accumulation rate,and a known condition of the accumulation register at t=0, the value inthe accumulation register will increase at a determinate rate and willcontain a known value at any given time t.

For example, assume that a continuous fault is measured at 70.71 amperes(RMS) with an accumulation period of 64 milliseconds. Further assumethat the accumulation register is at zero prior to the fault. Themicrocomputer 120 will accumulate the squared value of the current every64 milliseconds into the register, causing it to increase at a constantrate.

With a continuous, fixed level fault, as time increases, the internalaccumulation register increases proportionally. In order to protect thesystem from this fault, this increasing accumulated value is comparedperiodically against a predetermined threshold value that has beenchosen to represent the maximum allowed heat content of the system. Whenthe accumulated value equals or exceeds this predetermined thresholdvalue, the tripping system will trip the breaker.

A valuable aspect of accumulating the current squared value is that asthe current doubles, the current squared value quadruples and theinternal accumulation register increases at a more rapid rate, resultingin a more rapid trip. Thus, if the delay time (the period before thedetected power fault causes a trip) is x seconds at some current level,as the current doubles, the delay time will be x/4 seconds.

The formula for calculating the delay time for any constant current is:##EQU3## where:

A_(R) =the accumulation rate in seconds;

K=predetermined final accumulation value;

and

I=the true RMS value of current flowing through the breaker.

D. Reset Circuitry

Referring now to FIG. 8, an expanded view of the reset circuit 124 isshown to include a power-up reset circuit 710 and a watch-dog circuit712 to maintain the integrity of the tripping system 100. The power-upreset circuit 710 performs two functions, both of which occur duringpower-up: it provides a reset signal (asserted low) on line 743 tomaintain the microcomputer 120 in reset condition until the trippingsystem 100 develops sufficient operating power from the current lines106; and it provides a reset signal (asserted low) via lead 744 to thewatch-dog circuit 712 to prevent the watch-dog circuit from engaging thesolenoid 112 during power-up. This latter function prevents nuisancetripping.

Preferably the power-up reset circuit includes an under-voltage sensingintegrated circuit 745 that detects whether or not the output voltage ofthe +5 volt supply is less than a predetermined reference voltage atwhich the microcomputer (120 in FIG. 1) may properly function. Theintegrated circuit 745 is, for example, part No. MC33064P-5, which holdsthe reset line 743 low until the output voltage of the +5 volt supplyrises above 4.6 volts. The microcomputer 120 may operate at 4.5 volts orabove. The preferred reset circuit also includes a pull-up resistor 741,a capacitor 739, and a diode 753 connecting the integrated circuit 745to the watchdog circuit 712. The resistor 741, for example, has a valueof 47 K ohms and the capacitor 739 has a value of 0.01 microfarads. Thediode 753 ensures that the reset circuit 710 affects the watchdogcircuit 712 only when the microcomputer 160 is being reset.

The watch-dog circuit 712 protects the tripping system frommicrocomputer malfunctions. Thus, it is designed to engage the solenoid112 if the microcomputer 120 fails to reset the watch-dog circuit 712within a predetermined time period. The microcomputer 120 resets thewatch-dog circuit 712 by regularly generating logic high pulses,preferably about every 200 milliseconds, on lead 714. These pulses arepassed through a capacitor 718 to activate an IGFET transistor 720,which in turn discharges an RC timing circuit 724 through a circuitlimiting resistor 733. A resistor 730 and a clamping diode 732 are usedto reference the pulses from the capacitor 718 to ground.

The pulses on lead 714 prevent the RC timing circuit 724 from chargingup past a reference voltage, Vref, at the input of a comparator 726. Ifthe RC timing circuit 724 charges up past Vref, the comparator 726 sendsa trip signal to the solenoid 112 to interrupt the current path in lines106. The reference voltage, for example, is provided by a 4.3 volt zenerdiode 427 supplied with current through a resistor 729. Preferredcomponent values are, for example, 0.001 microfarads for capacitor 718,27 K ohms for resistor 730, part No. 1N4148 for diode 732, part No.BS170 for transistor 720, 10 ohms for resistor 733, 820 K megohms forresistor 737, 0.22 microfarads for capacitor 735, part No. LM29031 forcomparator 726, part No. 1N4687 for diode 727, 100 K ohms for resistor729, and 10 K ohms for resistor 751.

E. User Select Switches

As introduced above, the user select circuit 132 is illustrated in FIG.9. In addition to the buffer 820 for the rating plug, the user selectcircuit 132 includes a plurality of user interface circuits 810 eachhaving a pair of BCD dials 812 and a tri-state buffer 814 which isenabled through the address and data decoder 130 of FIG. 1. Each BCDdial 812 allows the user to select one of several tripping systemcharacteristics. For example, a pair of BCD switches may be used todesignate the longtime pickup and the longtime delay (overload trippingcharacteristics) and another pair of BCD switches may be used todesignate the short time pickup and the short time delay (short circuittripping characteristics). Other BCD switches may be used to designatesensor and breaker sizes, an instantaneous pickup, ground fault trippingcharacteristics, and phase unbalance thresholds.

F. Energy Validation For Solenoid Activation

The user select circuit 132 of FIG. 1 and 9 also determines if there issufficient energy to activate the solenoid 112. Using the address anddata decoding circuit 130, the buffer 820 is selected to read one of itsinput lines 830. The VT signal from the power supply 122 of FIG. 1 feedsthe input line 830, with the buffer 820 being protected from excessivevoltage by a resistor 832 and a clamping diode 834. The resistor 832,for example, has a value of 620 K ohms.

Before the microcomputer 120 engages the solenoid 112, the input line830 is accessed to determine if VT is read as a logic high or a logiclow. The buffer 820 provides a logic high at its output whenever theinput is greater than 2.5 v to 3 v. If VT is read as a logic high, themicrocomputer 120 determines that there is sufficient power to activatethe solenoid 112 and attempts to do so. If VT is read as a logic low,the microcomputer 120 determines that there is insufficient power toactivate the solenoid 112 and waits, while repeatedly checking VT, inanticipation that an intermittent power fault caused VT to fall. Once VTrises beyond the 2.5-3.0 volt level, the microcomputer 120 attempts toactivate the solenoid once again.

G. Communication For Information Display

The microcomputer 120 sends identical tripping system status informationto the local display 150 and the display terminal 162. The informationis sent synchronously on a serial peripheral interface 191 to the localdisplay 150 and asynchronously on a serial communication interface 151to the display terminal 162. The interfaces 151 and 191 may beimplemented using the SCI and SPI ports internal to the MC68HC11. Thehistory of the tripping system status information is stored in thenonvolatile trip memory 144. That history includes the specific causeand current level of the last trip and a running accumulation of thedifferent trip causes.

The trip memory 144 is preferably an electrically erasable programmableROM (EEPROM), for example, a X24CO4I, available from Xicor, Inc. ofMilpitas, Calif. In this case, the serial peripheral interface 191 isused for bidirectional data transfer between the microcomputer 120 andthe EEPROM 144. This data transfer is implemented using one line of theserial peripheral interface 191 to transfer the data and the other lineto transmit a clock signal between the microcomputer 120 and the EEPROM114 for synchronization. During power up of the tripping system 100, themicrocomputer 120 transmits to the trip memory 144 a unique bit patternwhich is interpreted as a data request code. The microcomputer 120 thensets the bidirectional data line as an input and clocks the requesteddata in from the trip memory 144.

The microcomputer 120 maintains a copy of the history data in itsinternal RAM and in the event of a trip, updates it and transmits itback into trip memory 144 via the interface 191, again utilizing theunique bit pattern to set the trip memory 144 to a receive mode. Uponreceipt of the data, trip memory 144 will reprogram its contents,overwriting the old history information with the newly received data.

During normal operation (i.e., after power up and without a trip), themicrocomputer 120 transmits operational information over the serialperipheral interface 191. Because this information does not contain theunique bit patterns required to activate the trip memory 144, the tripmemory 144 ignores the normal transmissions. However, other deviceswhich may be connected to the serial peripheral interface 191 canreceive and interpret the information correctly.

The microcomputer 120, for example, is programmed to execute acommunication procedure that permits the tripping system 100 tocommunicate with a relatively low power processor in the displayprocessor 316. The procedure utilizes a software interrupt mechanism totrack the frequency with which information is sent on the interfaces 151and 191. During normal operation, one 8-bit byte of information is sentevery seven milliseconds. During tripping conditions, information issent continuously as fast as the microcomputer 120 can transmit. Thisprocedure allows the display terminal 162 and the display processor 316to display continuously status messages from the tripping system 100without dedicating their processors exclusively to this receptionfunction. Equally important, this procedure permits the microcomputer120 to perform a variety of tasks, including continuous analysis of thecurrent on lines 106.

Status messages are preferably transmitted using an 8-byte per packet,multi-packet transmission technique. The type of information included ineach packet may be categorized into eight different groups, or eightdifferent packets, packet 0 through packet 7. The first byte of eachpacket is used to identify the byte and packet numbers and the tripstatus of the tripping system 100. For example, the first byte maycontain one bit to identify the byte type, four bits to identify thepacket number and three bits to identify the trip status: no tripcondition, current overload trip, short circuit trip, instantaneoustrip, ground fault trip and phase unbalance trip. Bytes two through sixof each packet vary depending on the packet number. Byte 7 is used toidentify the tripping system sending the information (for a multiplesystem configuration), and byte 8 is used as a checksum to verify theintegrity of the data.

The microcomputer alternates the type of information included in eachpacket, depending upon the priority type of the information. Duringnormal (non-tripping) conditions, the trip unit will transmit PacketNumber 0, followed by Packet Number 1, followed by one of the remainingdefined Packet Numbers, 2 through 7. The sequence is graphically shownas:

    ______________________________________                                        1)      Packet 0 - Packet 1 - Packet 2                                                                     Repeat until                                     2)      Packet 0 - Packet 1 - Packet 3                                                                     Trip                                             3)      Packet 0 - Packet 1 - Packet 4                                                                     Occurs                                           4)      Packet 0 - Packet 1 - Packet 5                                        5)      Packet 0 - Packet 1 - Packet 6                                        6)      Packet 0 - Packet 1 - Packet 7                                        ______________________________________                                    

During a trip condition, the normal operation packet transmissionsequence is interrupted and Packet number 2 is transmitted continuouslyuntil power is lost. The transmission rate will be increased to thefastest rate possible.

The five bytes of each packet that vary according to packet number areconfigured for a total of eight different packets, 0-7. The informationin these bytes is implemented for each packet number as follows:

    ______________________________________                                        Packet 0 - (0 0 0 0)                                                          Data Byte 1 -                                                                          Phase A Current - High Byte                                          Data Byte 2 -                                                                          Phase A Current - Low Byte                                           Data Byte 3 -                                                                          Phase B Current - High Byte                                          Data Byte 4 -                                                                          Phase B Current - Low Byte                                           Data Byte 5 -                                                                          Overload Pickups & Short Circuit Restraint In                        Packet 1 - (0 0 0 1)                                                          Data Byte 1 -                                                                          Phase C Current - High Byte                                          Data Byte 2 -                                                                          Phase C Current - Low Byte                                           Data Byte 3 -                                                                          Ground Fault Current - High Byte                                     Data Byte 4 -                                                                          Ground Fault Current - Low Byte                                      Data Byte 5 -                                                                          Short Circuit, Phase Unbalance & Ground Fault                                 Pickups                                                              Packet 2 - (0 0 1 0)                                                          Data Byte 1 -                                                                          Maximum Phase Current - High Byte                                    Data Byte 2 -                                                                          Maximum Phase Current - Low Byte                                     Data Byte 3 -                                                                          Maximum Phase Identification (A, B, C or N),                                  Breaker Identification & Ground Fault                                         Restraint In                                                         Data Byte 4 -                                                                          Trip Unit/Sensor Identification                                      Data Byte 5 -                                                                          Rating Plug/Options                                                  Packet 3 - (0 0 1 1)                                                          Data Byte 1 -                                                                          Long Time Switches                                                   Data Byte 2 -                                                                          Short Time Switches                                                  Data Byte 3 -                                                                          Instantaneous Phase Unbalance Switches                               Data Byte 4 -                                                                          Ground Fault Switches                                                Data Byte 5 -                                                                          Phase Unbalance Trips                                                Packet 4 - (0 1 0 0)                                                          Data Byte 1 -                                                                          Long Time Trips                                                      Data Byte 2 -                                                                          Short Circuit Trips                                                  Data Byte 3 -                                                                          Ground Fault Trips                                                   Data Byte 4 -                                                                          Last Maximum Phase Current - High Byte                               Data Byte 5 -                                                                          Last Maximum Phase Current - Low Byte                                Packet 5 - (0 1 0 1)                                                          Data Byte 1 -                                                                          Software Failure Trips                                               Data Byte 2 -                                                                          Last Phase A Current - High Byte                                     Data Byte 3 -                                                                          Last Phase A Current - Low Byte                                      Data Byte 4 -                                                                          Last Phase B Current - High Byte                                     Data Byte 5 -                                                                          Last Phase B Current - Low Byte                                      Packet 6 - (0 1 1 0)                                                          Data Byte 1 -                                                                          Last Fault System Status Byte                                        Data Byte 2 -                                                                          Last Phase C Current - High Byte                                     Data Byte 3 -                                                                          Last Phase C Current - Low Byte                                      Data Byte 4 -                                                                          Last Ground Fault Current - High Byte                                Data Byte 5 -                                                                          Last Ground Fault Current - Low Byte                                 Packet 7 - (0 1 1 1)                                                          Data Byte 1 -                                                                          Long Time Memory Ratio                                               Data Byte 2 -                                                                          Phase A % Unbalance                                                  Data Byte 3 -                                                                          Phase B % Unbalance                                                  Data Byte 4 -                                                                          Phase C % Unbalance                                                  Data Byte 5 -                                                                          Software Version Identifier Byte                                     ______________________________________                                    

Accordingly, the microcomputer 120 transmits information in foursubstantive classes. The first class constitutes trip statusinformation, as set forth in the first byte of each pocket. The secondand third classes involve current measurement information; and thesecond class including current measurement information on each line 106,as set forth in packets 0 and 1, and the third class including maximumcurrent status information, as set forth in packet 2. The last class ofinformation relates to the present configuration of the tripping systemand is contained in packets 3 through 7.

H. Appendices

The attached appendices respectively illustrate the preferred manner inwhich the microcomputer 120 of FIG. 1 and the display processor 316 ofFIG. 3a may be programmed to implement the system as set forth above inthe preferred embodiment.

I claim:
 1. For use in a processor-based circuit breaker tripping systemhaving a current sensor for sensing current in a current path, a ratingplug circuit comprising:a circuit board; resistor means, connected tothe circuit board, for establishing a voltage in a predetermined ratioto the amount of sensed current; a connector, having a plurality ofconductive contact points, for interconnecting the circuit board withthe tripping system; and coding means, coupled to the conductive contactpoints, for establishing a code representing said predetermined ratio ofsaid voltage to the sensed current; wherein the code is capable of beingread by the processor via the connector to analyze the current path. 2.A rating plug circuit, according to claim 1, wherein the coding meansincludes a plurality of printed circuit paths disposed on the circuitboard and connected to various ones of the conductive contact points ofthe connector to establish the code.
 3. A rating plug circuit, accordingto claim 2, wherein the resistor means includes a plurality ofresistors, each of which is connected to a respective one of theconductive contact points at one end and to a common one of the contactpoints at the other end, to thereby provide the tripping system with arespective resistor for each of a plurality of phases of current in thecurrent path.
 4. For use in a fault-powered, processor-based circuitbreaker tripping system having a current sensor for sensing current in acurrent path, a rating plug circuit comprising:a printed circuit board;resistor means, connected to the printed circuit board, for establishinga voltage in a predetermined ratio to the amount of sensed current; aconnector, having a plurality of conductive contact points, forinterconnecting the printed circuit board with the tripping system; anda plurality of printed circuit paths disposed on the printed circuitboard and connected to various ones of the conductive contact points ofthe connector for establishing a binary code representing saidpredetermined ratio of said voltage to the sensed current; wherein thebinary code is capable of being read by a processor via the connector toanalyze the current path.
 5. For use in a processor-based circuitbreaker tripping system having a current sensor for sensing current froma current path, a method for establishing a current rating for thetripping system comprising the steps of:defining a plurality of printedcircuit paths to various conductive contact points on a printed circuitboard; connecting a resistor to the printed circuit board to establish avoltage in a predetermined ratio to the amount of sensed current;opening selected ones of the plurality of printed circuit paths toestablish a binary code representing said predetermined ratio of saidvoltage to the sensed current; interconnecting the printed circuit boardwith the tripping system using a connector having a plurality ofconductors connected to the conductive contact points; using logicmeans, coupled to the plurality of printed circuit paths, to establishlogic high and logic low levels on the conductive contact pointsindicating said binary code; using the resistor to scale the sensedcurrent; and using a processor to read said logic high and low level toobtain said binary code and analyze the sensed current having beenscaled by the resistor.
 6. A method, according to claim 5, wherein thestep of opening the selected ones of the plurality of printed circuitpaths includes applying an excessive amount of current therethrough. 7.For use in a processor-based circuit breaker tripping system having acurrent sensor for sensing current from a current path, a method formanufacturing a rating plug circuit, comprising the steps of:defining aplurality of printed circuit paths to various conductive contact pointson a printed circuit board; connecting an electrical connector to thecontact points on the printed circuit board; connecting a resistorhaving a selected value to the printed circuit board; and openingselected ones of the plurality of printed circuit paths to provide acode indicating the selected value of the resistor.
 8. A method formanufacturing a rating plug circuit, according to claim 7, wherein thestep of opening the selected ones of the plurality of printed circuitpaths includes applying an excessive amount of current therethrough. 9.For use in a processor-based circuit breaker tripping system having acurrent sensor for sensing current in a current path, a rating plugcircuit comprising:resistor means for establishing a voltage in apredetermined ratio to the amount of sensed current; a connector forinterconnecting the rating plug circuit with the tripping system; andcoding means, coupled to said connector, for establishing a coderepresenting said predetermined ratio of said voltage to the sensedcurrent, the code capable of being read by the tripping system via saidconnector.
 10. A rating plug circuit, according to claim 9, wherein theresistor means includes a plurality of resistors, wherein the trippingsystem is provided with a respective resistor for each of a plurality ofphases of current in the current path.
 11. For use in a processor-basedcircuit breaker tripping system having a current sensor for sensingcurrent in a current path, a rating plug circuit for setting a currentrating for the tripping system, comprising:a circuit board; resistormeans, connected to the circuit board, for establishing a voltage in apredetermined ratio to the amount of sensed current so as to establish amaximum allowable continuous current passing through the current path; aconnector, having a plurality of conductive contact points, forinterconnecting the circuit board with the tripping system so as toestablish a maximum current rating for the tripping system, such that anabsence of the rating plug circuit from the tripping system causes thetripping system to revert to a minimum current rating; and coding means,coupled to the conductive contact points, for establishing a coderepresenting said predetermined ratio of said voltage to the sensedcurrent; wherein the code is capable of being read by the processor viathe connector to analyze the current path.
 12. A rating plug circuit,according to claim 11, wherein the coding means includes a plurality ofprinted circuit paths disposed on the circuit board and connected tovarious ones of the conductive contact points of the connector toestablish the code.
 13. A rating plug circuit, according to claim 12,wherein the coding means includes a plurality of fusible printed circuitlinks which are selectively disconnected from said plurality of printedcircuit paths to establish the code, thereby informing the processor ofsaid predetermined ratio of said voltage to the sensed current.
 14. Arating plug circuit, according to claim 13, wherein said plurality ofprinted circuit paths are connected to a logic-circuit voltage signalvia one of the conductive contact points on said connector so as toallow the tripping system to encode said plurality of printed circuitlinks in binary logic.
 15. A rating plug circuit, according to claim 11,wherein the resistor means includes a plurality of resistors, each ofwhich is connected to a respective one of the conductive contact pointsat one end and to a common one of the contact points at the other end,to thereby provide the tripping system with a respective resistor foreach of a plurality of phases of current in the current path.
 16. Arating plug circuit, according to claim 15, wherein the coding means iscapable of informing the processor of the resistor values.